Refrigerator-stable pancake &amp; waffle batter in a pressurized can

ABSTRACT

An unpasteurized pancake and waffle batter is provided in a pressurized dispenser and can be used to bake a variety of food products. In embodiments of the present invention, raw ingredients including flour, sugar and egg are mixed with water in a cold process to create a batter having a water activity of approximately 0.96. The batter is sealed in a dispenser and pressurized with a gas such as carbon dioxide. The carbon dioxide reduces the viscosity of the batter to allow the batter to be dispensed for the life time of the product. The carbon dioxide aerates the food product giving light and fluffy baked products and also serves as a browning agent.

PRIORITY CLAIM

The present application claims priority to U.S. patent application Ser.No. 11/760,647 entitled “REFRIGERATOR STABLE PRESSURIZED BAKING BATTER”filed Jun. 8, 2007 which claims priority to U.S. Provisional PatentApplication No. 60/812,674, entitled “REFRIGERATOR STABLE PRESSURIZEDBAKING BATTER”, inventors: Sean Francis O'Connor and Nathan Steck, filedJun. 9, 2006, both of which applications are incorporated herein byreference.

FIELD OF THE INVENTION

The present invention is directed to food products, specificallypre-mixed or ready to cook batters and dough.

BACKGROUND OF THE INVENTION

A number of different types of food products come in pressurizeddispensers, including decorative icings, dessert toppings, whippingcream, whipped cream substitute and Cheez Whiz®, a thick sauce productmade by Kraft Foods®.

Consumers have come to find foods provided in pressurized cans to beconvenient to use. Hence, different foods provided in such a manner areadvantageous. Typically, dough and batter used in baking comes in dryform or must be assembled from component ingredients from scratch.

SUMMARY OF THE INVENTION

Although a number of inventors have proposed bakable batters in apressurized can, there is no commercially successful product currentlyon the market. This reflects the problem in developing a batter that hasan acceptable shelf storage life in a pressurized can, the ability tofreeze store the product without deleterious separation of components,obtaining an attractively browned appearance, a palatable taste andlight and fluffy texture when baked.

In various embodiments of the present invention, a cold process ofpreparing a food product to be provided in a pressurized can without theneed for pasteurization of the ingredients results in a refrigerationstable product. In various embodiments of the present invention, a coldprocess of preparing a food product to be provided in a pressurized canwithout the need for pasteurization of all of the ingredients results ina refrigeration stable product. In various embodiments of the presentinvention, the ingredients include a browning agent which is used tocontrol the appearance and texture of the product. In variousembodiments of the present invention, the ingredients enable freezingand thawing of the product without phase separations. In variousembodiments of the present invention, a browning agent is used which iscompatible with the cold process and pressurized can application of theproduct. In various embodiments of the present invention, theingredients used to allow freezing and thawing are compatible with oneor more of the browning agent, the cold process preservation andpressurized can application of the product. In various embodiments ofthe present invention, the ingredients stored in the can include one ormore preservative. In various embodiments of the present invention,different baking products including waffles, pancakes, muffins, cupcakes, ginger bread, cookies and brownies are formulated using the coldprocess into a ready to use pressurized can and dispensed directly intothe cooking apparatus. In various embodiments of the present invention,the batter in the can be combined with gasses and a water-mixed drybatter recipe under pressure.

BRIEF DESCRIPTION OF THE FIGURES

This application contains at least one drawing or photograph executed incolor. Copies of this patent application publication with colordrawing(s) will be provided by the Office upon request and payment ofthe necessary fee.

This invention is described with respect to specific embodimentsthereof. Additional aspects can be appreciated from the Figures inwhich:

FIG. 1 shows a flow chart outlining the steps involved in preparing thebatter for dispensing;

FIG. 2 shows the Change in Pressure in Un-pressurized Cans (Dots—0.15%Sorbates, no N₂ Cap; Vertical Lines—0.15% Sorbates, N₂ Cap; HorizontalLines—0.15% Sorbates, 1.0% Lactic acid, no N₂ Cap; Black—0.15% Sorbates,1.0% Lactic acid, N₂ Cap);

FIG. 3 shows the Change in Pressure in CO₂ Pressurized Cans (Dots—1.0%Sorbates; Vertical Lines—1.0% Sorbates, 200 ppm EDTA; HorizontalLines—1.0% Sorbates, 500 ppm EDTA; Diagonal Stripes LtoR—1.0% Sorbates,0.1% Sodium benzoate; Black—1.0% Sorbates, 0.075% Propyl Paraben, 0.025%Methyl Paraben; Diagonal Stripes RtoL—1.0% Sorbates, 0.5% Lactic acid;White—1.0% Sorbates, 1.0% Lactic acid);

FIG. 4 shows the Change in Pressure in N₂ Pressurized Cans (Dots—1.0%Sorbates; Vertical Lines—1.0% Sorbates, 200 ppm EDTA; HorizontalLines—1.0% Sorbates, 500 ppm EDTA; Diagonal Stripes LtoR—1.0% Sorbates,0.1% Sodium benzoate; Black—1.0% Sorbates, 0.075% Propyl Paraben, 0.025%Methyl Paraben; Diagonal Stripes RtoL—1.0% Sorbates, 0.5% Lactic acid;White—1.0% Sorbates, 1.0% Lactic acid); and

FIG. 5 shows a comparison between waffles (10 and 30) and pancakes (20and 40), where the waffles and pancakes are baked using batter mixed anddispensed with carbon dioxide from a pressurized canister (10 and 20) orthe batter is not mixed or dispensed with carbon dioxide but applieddirectly to the waffle iron or frying pan (30 and 40).

DETAILED DESCRIPTION OF THE INVENTION

In an embodiment of the present invention, a batter mix such as thatwhich can be useful for making pancakes, waffles, muffins, cup cakes,ginger bread, cookies and brownies can be mixed with water andtransferred to a can. In an embodiment of the present invention, anantibacterial agent can be added to the batter and transferred to a can.In an embodiment of the present invention, a can or container can besealed and pressurized with a mixture of water soluble and nonwater-soluble gasses. In an embodiment of the present invention, thepressurized gasses are a mixture of N₂ and CO₂. In an alternativeembodiment of the invention, the pressurized gas is 100% CO₂. In anembodiment of the present invention, the antibacterial agent can becultured dextrose. In an alternative embodiment of the invention, theantibacterial agent is sodium lactate. In various embodiments of thepresent invention, the ingredients include a browning agent which isused to control the appearance and texture of the product. In variousembodiments of the present invention, the ingredients enable freezingand thawing of the product without phase separations. In variousembodiments of the present invention, a browning agent is used which iscompatible with the cold process and pressurized can application of theproduct. In various embodiments of the present invention, theingredients used to allow freezing and thawing are compatible with oneor more of the browning agent, the cold process preservation process andthe pressurized can application of the product. A dispenser suitable foruse in storing and dispensing the batter provided therein is well knownin the industry and to consumers alike, and includes a spout, whichreleases pressurized contents when an individual depresses the spout toexpend the contents of the can. There are numerous variations on theshape and type of dispenser, suitable for use with the presentinvention. The inventors have empirically determined that providing arefrigeration-stable, bakable batter in a pressurized can, using thespecified gas and pressure combinations set forth herein, produces asuperior quality baked good when the product is cooked in a mannersimilar to current dry mix products stored in boxes or bags.

The mix recipe can be used to create pancakes (single sided grilling) orwaffles (double sided, patterned grilling). The resultant product yieldsfluffy pancakes and light crisp waffles. In an embodiment of the presentinvention, the fluffy nature of the pancakes can be a result of thepartial pressures of the gasses used to pressurize the can. In anembodiment of the present invention, the fluffy nature of the pancakescan be a result of the partial pressure of the water soluble gasses usedto pressurize the can. In an embodiment of the present invention, thefluffy nature of the pancakes can be a result of the incorporation ofthe water-soluble gas into the batter mix. In an embodiment of thepresent invention, the fluffy nature of the pancakes can be a result ofthe ratio of the water to batter mix.

In an embodiment of the present invention, FIG. 1 shows a flow chart forassembling a charged batter-filled food in a pressurized container.Generally, the batter recipe will be blended at step 10, mixed withwater and preservatives at step 12, inserted into a pressurized sealablecontainer at step 14, the container sealed at step 16, and the containerpressurized in accordance with well-known techniques at step 18. In anembodiment of the present invention, steps 10-14 are carried out in aninert atmosphere. In an embodiment of the present invention, steps 10-14are carried out at between 32-48° F. In an alternative embodiment of thepresent invention, steps 12-14 are carried out at between 38-44° F.

In an embodiment of the present invention, the ingredients of the mixinclude wheat flour, sugar, nonfat dry milk, whole dried egg, salt,sodium bicarbonate, dicalcium phosphate dihydrate, xanthan gum, cultureddextrose and water. This recipe is mixed by blending all the dryingredients, adding water at approximately 1° C. (34° F.) to thecultured dextrose and then this solution to the dry blend in anappropriate amount (set forth below) depending on the desired batterproduct while keeping the temperature of the batter below approximately4° C. (40° F.). The batter can be stored in an inert atmosphere whilebeing transferred to piston fillers used to dispense the batter into theaerosol line for filling the pressurized cans.

In an alternative embodiment of the invention, the ingredients arecertified organic. The organic ingredients of the mix include wheatflour, sugar, whole dried egg, powdered soy, salt, sodium bicarbonate,dicalcium phosphate dehydrate, sodium lactate and water. This recipe ismixed by blending all the dry ingredients, adding water at approximately1° C. (34° F.) to the sodium lactate and then this solution to the dryblend in an appropriate amount (set forth below) depending on thedesired batter product while keeping the temperature of the batter belowapproximately 4° C. (41° F.). The batter can be stored in an inertatmosphere while being transferred to piston fillers used to dispensethe batter into the aerosol line for filling the pressurized cans.

In an embodiment of the present invention, the pressurized gas (100%CO₂) is used as a preservative of the ingredients stored in the can. Inan embodiment of the present invention, sodium lactate can be used as apreservative of the ingredients stored in the can. In an embodiment ofthe present invention, the pressurized gas (100% CO₂) and sodium lactatecan be used as preservatives of the ingredients stored in the can. In analternative embodiment of the present invention, sorbic acid can be usedas a preservative of the ingredients stored in the can. In an embodimentof the present invention, potassium sorbate can be used as apreservative of the ingredients stored in the can. In an embodiment ofthe present invention, propionic acid can be used as a preservative ofthe ingredients stored in the can.

In an embodiment of the present invention, the mix utilized for thepresent invention can be a specially blended mix. In an embodiment ofthe present invention, the mix utilized for the present invention can bean organic batter blended mix. In an embodiment of the presentinvention, the product produced with an organic batter blended mix canbe an organic product. In an embodiment of the present invention, otherdry mix can be utilized for the present invention. In an embodiment ofthe present invention, other dry-mix products can be utilized with thepresent invention. In an embodiment of the present invention, the drymix can be activated by a combination of water, milk or other fluids.

Table 1.0 outlines the breakdown of the total calories in a 100 g (3.53oz.) serving of the mixed pancake batter.

TABLE 1.0 Nutritional Analysis per 100 g Calories 130 cal Fat Calories10 cal Sat Fat Calories 0 cal Total Fat 1 g Saturated Fat 0 g StearicAcid 0 g Trans Fatty Acids 0 g Polyunsaturated Fat 0 g Omega 6 0 g Omega3 0 g Monounsaturated Fat 0 g Cholesterol 15 mg Sodium 160 mg Potassium0 g Total Carbohydrate 28 g Dietary Fiber 4 g Soluble Fiber 0 gInsoluble Fiber 0 g Sugars 4 g Sugar Alcohol 0 g Other Carbohydrate 20 gProtein 4 g Vitamin A 0% DV Vitamin A (RE) RE Vitamin C 0% DV Calcium 2%DV Iron 10% DV  Vitamin D 0% DV Vitamin E 0% DV Vitamin K 0% DV Thiamin0% DV Riboflavin 0% DV Niacin 0% DV Vitamin B6 0% DV Folate 0% DVVitamin B12 0% DV Biotin 0% DV Pantothenic Acid 0% DV Phosphorous 0% DVIodine 0% DV Magnesium 0% DV Selenium 0% DV Copper 0% DV Manganese 0% DVChromium 0% DV Molybdenum 0% DV Chloride 0% DV

Processing Procedure

In an embodiment of the present invention, a dry mixing vessel can beused to blend all the ingredients. In an embodiment of the presentinvention, water at approximately 1° C. (34° F.) can be added to the drymix. In an embodiment of the present invention, the batter can beblended for approximately 5 to 7 minutes on a high sheer mixer. In anembodiment of the present invention, the batter can be blended untilsmooth without lumps on a high sheer mixer. In an embodiment of thepresent invention, the batter can be blended at less than 4° C. (40° F.)on a high sheer mixer. In an embodiment of the present invention, thebatter can be stored in an inert atmosphere directly after mixing untilbeing loaded in pressurized cans. In an embodiment of the presentinvention, the batter can be stored under nitrogen to prevent the sodiumbicarbonate reaction for early leavening. In an embodiment of theinvention, the batter is not stored under nitrogen because the sodiumbicarbonate is encapsulated. Encapsulated sodium bicarbonate does notrelease until it reaches 58-61° C. (136-142° F.) directly after mixingand before being loaded in the pressurized cans. In an embodiment of thepresent invention, the batter can be pumped to piston fillers on anaerosol line prior to being loaded in the pressurized cans.

Cold Process Procedure

In an embodiment of the present invention, the blending of theingredients can be carried out in a refrigerated production room. In anembodiment of the present invention, the blending of the water and thedry ingredients can be carried out in a chilled production room. In anembodiment of the present invention, the blending of the water and thedry ingredients can be carried out with refrigerated productionequipment. In an embodiment of the present invention, the blending ofthe water and the dry ingredients can be carried out with refrigeratedproduction equipment in a refrigerated production room. In an embodimentof the present invention, the batter temperature can be controlled tonot exceed approximately 10° C. (50° F.). In an alternative embodimentof the present invention, the batter temperature can be controlled tonot exceed approximately 4° C. (40° F.). In an embodiment of the presentinvention, in a jacketed mixing tank the water coolant can be introducedat approximately 1±2° C. (34±2° F.). In an embodiment of the presentinvention, full scrape mix agitator can be utilized in mixing theingredients. In an embodiment of the present invention, high shear cageagitator can be utilized in mixing the ingredients. In an embodiment ofthe present invention, the dry blend of ingredients can be slowly pumpedinto the mixing vessel with slow agitation for approximately 10 minutes.In an embodiment of the present invention, batter can be mixed forapproximately 5 to 7 minutes on high shear speed, where the battertemperature is not allowed to exceed approximately 4° C. (40° F.).

In an embodiment of the present invention, cultured dextrose(0.10-3.00%) can be added to the water to be mixed with the dryingredients. In an embodiment of the present sodium lactate (belowapproximately 1%) can be added to the water prior to agitation with thedry mix to minimize ‘off-flavor’. In an embodiment of the presentinvention, cultured dextrose (greater than approximately 0.5%) can beadded to the water prior to agitation with the dry mix to insure 120 dayrefrigerated ‘shelf life’. In an embodiment of the present invention,cultured dextrose (0.50-1.00%) can be added to the water prior toagitation with the dry mix. In an alternative embodiment of the presentinvention, sodium lactate and carbon dioxide can be added to the batterprepared with the cold process to a insure 120 day refrigerated ‘shelflife’.

In various embodiment of the present invention, the water ranges fromapproximately 20% to approximately 80% of the dry batter weight (on a %by weight basis) for waffles, pancakes, muffins, cup cakes, and gingerbread, cookies and brownies formulations. In an embodiment of thepresent invention, a cookie mix can be made by mixing approximately 20%water with approximately 80% dry mix. In an embodiment of the presentinvention, a brownie mix can be made by mixing approximately 30% waterwith approximately 70% dry mix. In an embodiment of the presentinvention, a cup cake mix can be made by mixing approximately 30% waterwith approximately 70% dry mix. In an embodiment of the presentinvention, a pancake mix can be made by mixing approximately 50% waterwith approximately 50% dry mix. In an embodiment of the presentinvention, a waffle mix can be made by mixing approximately 60% waterwith approximately 40% dry mix. In an embodiment of the presentinvention, a moose mix can be made by mixing approximately 80% waterwith approximately 20% dry mix. In an alternative embodiment of thepresent invention, the water can be 43% by weight of the mix forwaffles, pancakes, muffins, cup cakes, ginger bread, cookies andbrownies.

In various embodiments of the invention, the ratio of water to dry mixvaries depending on the nature of the dry mix. All-purpose flour haslower levels of gluten and as a result requires less water. In contrast,pastry flour has higher levels of gluten, which requires more water togenerate the same consistency mix. In an embodiment of the presentinvention, the water is 60% by weight for waffles using an ‘organic’batter mix. In an embodiment of the present invention, the water is 40%by weight for waffles using a non-organic dry mix containing all-purposeflour.

In an embodiment of the present invention, the water varies depending onthe required consistency of the product. In an embodiment of the presentinvention, a pancake mix can be made by mixing approximately 50% waterwith approximately 50% dry mix. In an embodiment of the presentinvention, the pancake mix can vary between 40.5-52.5% by weight waterdepending on the required consistency. In an embodiment of theinvention, one mix can be used for both waffles and pancakes.

In an embodiment of the present invention, the dry mix ingredients aregreater than 95% organic. In an embodiment of the invention, there areno available substitute organic ingredients for the non-organicingredients in the dry mix. In an embodiment of the invention, where thedry mix ingredients are greater than 95% organic and there are noavailable substitute organic ingredients for the non-organicingredients, the food product can be certified as organic.

In an embodiment of the present invention, an amount of sorbic acid canbe used to adjust the pH of the batter mix. In an embodiment of thepresent invention, an amount of potassium sorbate can be used to adjustthe pH of the batter mix. In an embodiment of the present invention, theinclusion of one or more ingredients to control the pH in the batterprovides a stable product, requiring refrigeration at approximately 4±2°C. (40±2° F.). In an embodiment of the present invention, the water tobe added to the dry mix can be provided with approximately 0.1%potassium sorbate and approximately 0.05% sorbic acid (by weight).

In an embodiment of the present invention, an amount of potassiumsorbate controls the growth of yeast and mold to keep the productstable. In an embodiment of the present invention, sodium lactatecontrols the growth of yeast, mold lactic acid and Listeria to keep theproduct stable. In an embodiment of the present invention, an amount ofcultured dextrose controls the growth of yeast and mold to keep theproduct stable. In an embodiment of the present invention, the inclusionof one or more ingredients to control the growth of mold and bacteria inthe batter provides a stable product, requiring refrigeration atapproximately 4±2° C. (40±2° F.).

In an embodiment of the present invention, batter can be pumped to ajacketed holding vessel, where the batter temperature is not allowed toexceed 4±2° C. (40±2° F.). In an embodiment of the present invention,batter can be pumped to a series of filling heads. In an embodiment ofthe present invention, sanitized lined cans can be introduced to theseries of filling heads and filled with the batter. In an embodiment ofthe present invention, cans can be valved with tilt valve 2×0.0022 orvertical action valve 2×0.033×0.090 valves and the cans can be crimpedand gassed to approximately 150±3 psi. Cans can be tipped, capped,packed and stored in cold storage at 4±2° C. (40±2° F.).

In various embodiments of the present invention, different bakingproducts including waffles, pancakes, muffins, cup cakes, ginger bread,cookies and brownies are formulated using the cold process into a readyto use pressurized can and dispensed directly into the cookingapparatus.

The pressurizing step provides with different mixtures of a pressurizedgas, depending on the particular application for the batter in the can.If the batter is to be used as a waffle mix, the gas can be nitrogen(N₂) and carbon dioxide (C0₂) mixed in a ratio of approximately 10% N₂and approximately 90% C0₂ by weight, pressurized at 150 pounds persquare inch (psi). For a pancake mix, the gas can be N₂ and C0₂ mixed ina ratio of approximately 50% each gas by weight. For a cup cake mix, thegas can be N₂ and C0₂ mixed in a ratio of approximately 55% N₂ andapproximately 45% C0₂ by weight. For a brownie mix, the gas can be N₂and C0₂ mixed in a ratio of approximately 85% N₂ and approximately 15%C0₂ by weight.

In an alternative embodiment of the invention, if the batter is to beused as a waffle mix, the gas can be 100% carbon dioxide (C0₂),pressurized at 150 pounds per square inch (psi). See Table 14.2 for theweight of gas added in the can.

Different batter mixtures require various pressurizing reagents andcompositions in order to provide the optimal consistency for baking ofthe food product. For example, the batter in a gas container can bepressurized with carbon dioxide (C0₂). C0₂ is a water miscible orsoluble gas. After sealing the can, the pressure drops considerably (upto approximately 40%) after canning because the CO₂ dissolves into themixed batter in the can. For a waffle mix where the gas is 90% C0₂ thiscan have a significant impact on the final pressure. For a pancake mix,the gas composition can include both nitrogen (N₂) and C0₂. In contrast,to C0₂, N₂ is largely a non water-soluble gas. When N₂ and C0₂ are mixedin a ratio range of approximately 90% nitrogen and approximately 10%carbon dioxide to approximately 80% nitrogen and approximately 20%carbon dioxide, the N₂ will not be significantly absorbed by the battermix, and the resulting total pressure can remain higher. By havingapproximately 10% to approximately 20% of the gas as C0₂, thiscombination gives sufficient gas emulsification of the batter togenerate a light and fluffy pancake or waffle, while maintainingsufficient gas pressure for the entire life of the can. Gas compositionand ratios for muffins are similar to waffles. Gas compositions andratios for ginger bread, cookies and brownies formulations are similarto pancakes.

The foregoing detailed description of the invention has been presentedfor purposes of illustration and description. It is not intended to beexhaustive or to limit the invention to the precise form disclosed. Manymodifications and variations are possible in light of the aboveteaching. The described embodiments were chosen in order to best explainthe principles of the invention and its practical application to therebyenable others skilled in the art to best utilize the invention invarious embodiments and with various modifications as are suited to theparticular use contemplated. It is intended that the scope of theinvention be defined by the claims appended hereto.

A bakable food product is any food product which requires heating priorto serving. Bakable includes processes such as frying, poaching,grilling, bar-b-q-ing, heating in a waffle iron, heating in a sandwichmaker, heating in a boiler, heating in a conventional oven, heating in agas convection oven, heating in a microwave oven and heating in atoaster.

Example 1

Aim: to determine an acceptable pancake powder mix to water ratio; anddetermine suitable propellant(s) to make an aerosol packaged pancakebatter.

Mix: 50/50 Elite Spice Pancake Mix/DI Water (˜50° C.; ˜120° F.);Preservatives (0.05% Potassium sorbate and 0.05% sorbic acid); Fill: 16oz; Can: 214×804, 3-piece, lined; Propellants Tested:

(i) 5 g Carbon Dioxide (CO₂), (ii) 2.8 g Nitrogen (N₂)

TABLE 1.1 Cook Test Results on the Aerosol Packaged Batter AmountDispensed, g Appearance of Pancakes Samples gassed with 5.0 g CO₂ 32thinner pancakes Samples gassed with 2.8 g N₂ 58 thicker, “sponge-like”pancakes

Although different amounts of batter were dispensed with the differentpropellants (see Tables 1.1 and 1.2), the samples made similar diameterpancakes. This is due to the CO₂ dissolved (in water) in the CO₂ samplethat gave the batter more volume.

TABLE 1.2 Spray Rates of Aerosol Packaged Batter Pressure after 17 Spraydays, psi Rate, g/s Samples gassed with 5.0 g CO₂ 45 psi 10.8 Samplesgassed with 2.8 g N₂ 95 psi 12.0

Initial tests showed that the ratio of 50/50 Elite Spice powdermix-to-water ratio made a batter that produced good pancakes andwaffles. The consistency was typical of a pancake batter.

These samples were used to cook pancakes and waffles (using waffleiron). The sample gassed with CO₂ was more suitable to make waffles. Thewaffles produced were light and crispy. Because CO₂ is more soluble inwater than N₂, the batter dispensed from the CO₂-gassed sample haddissolved CO₂ in it. When cooked in the waffle iron, the CO₂ escapedmaking the waffle light, thin and crispy. When this sample was used tomake pancakes, the dissolved CO₂ escaped the batter during the cookingprocess making the pancakes flat and thin. The sample gassed with N₂made better pancakes than the one gassed with CO₂. The N₂ pressurizedthe can, but did not really get absorbed or mixed in the water/batter.The batter dispensed was therefore denser and made thicker, sponge-likepancakes similar in appearance and texture to normal pancakes. When thissample was used to cook waffles, the waffles produced were thicker anddenser. The test candidate preferred the thin and crispy waffles overthe denser ones. On the other hand, they preferred the denser pancakesover the thin and flat ones. Summary of trial: samples gassed with CO₂made good waffles; samples gassed with N₂ made good pancakes.

Example 2

Aim: to fine-tune the powder mix-to-water ratio and the amount ofcompressed gas to be used as propellant.

The following samples were prepared: (i) 50 powder mix/50 water; in214×804 can; filled at 16 oz; gassed with 3.9 g N₂ at 130 psi; (ii) 45powder mix/55 water; in 205×604 can; filled at 4 oz; gassed with 2.7 gN₂ at 130 psi; and (iii) 40 powder mix/60 water; in 214×804 can; filledat 12 oz; gassed with 4.6 N₂ at 130 psi. Additionally, the followingsamples were prepared for test candidate testing: (iv) 50 powder mix/50water; gassed with CO₂; (v) 47.5 powder mix/52.5 water; gassed with N₂.

Results: As in Example 1, sample (iv) that was 50/50 and gassed with CO₂made thin, light and crispy waffles. Sample (v), that was 47.5% powdermix and 52.5% water was found to be less dense than sample (iv) and waseasier to mix. Sample (v) also flowed faster and easier from the cangassed with N₂ and still made pancakes with attractive appearance, tasteand texture. The quality of the pancake was comparable to sample (i)where the 50/50 formula was gassed with N₂. Test candidate test result:sample (iv) 50/50 with CO₂—good for waffles; sample (v) 47.5/52.5 withN₂—good for pancakes.

TABLE 2.1 Cook Test Results on N₂-Pressured Pancake Batter with VaryingPowder Mix-to-Water Ratio. Powder Mix-to- Water ratio Can Fill, ozPropellant Results 50/50 214 × 804 16 3.9 g N₂ gassed batter was dense;the at 130 psi pancakes were sponge- like as typical pancakes 45/55 205× 604 4 2.7 g N₂ gassed batter was less dense; at 130 psi cookedpancakes looked like typical pancakes (sponge-like with bigger airpockets) 40/60 214 × 804 12 4.6 g N₂ gassed batter was thin and runny at130 psi

Example 3

Aim: to conduct preliminary tests on different preservatives.

Mix: Pancake Batter: 47.5/52.7 Elite Spice Pancake Mix/DI Water. Screwcap glass vials. Primary Preservatives used: (i) 0.05% Sorbic Acid and0.10% Potassium Sorbate; (ii) 0.10% Sorbic Acid and 0.20% PotassiumSorbate. Additional preservatives: EDTA, Sodium Benzoate, MethylParaben, Propyl Paraben and Lactic Acid All the samples were asepticallyprepared. One set of vials were capped with N₂ and one set was not. Allthe vials were stored in the dark at room temperature for 1 week.

Results: The evaluation of the samples was limited to visual andolfactory testing. Based on these results, no preservative was suitablefor the required batter applications. The results were almost identicalin all the samples regardless of the preservative system used. Allsamples showed signs of phase separation, pressure built up and a sourodor was detected after a week. The phase separation was expected insuch suspension with high level of water insoluble solids. The battermixture can require an emulsifier or a suspending agent. The pressurebuild-up can have been due to: generation of CO₂ from bicarbonateleavening agent and/or microbial growth and/or possible fermentation.The souring of odor could have been due to fermentation or othermicrobial growth. The microorganisms can have come from powder mix.

TABLE 3.1 Preservative Test Results on Pancake Batter in Glass Vialswith 0.05% Sorbic Acid and 0.10% Potassium Sorbate After 1 WeekAdditional Preservatives Air Headspace N₂ Headspace None no phaseseparation phase separation pressure build-up pressure build-up sourmilk odor sour milk odor 200 ppm EDTA beginning of phase phaseseparation separation pressure build-up pressure build-up sour milk odorsour milk odor 500 ppm EDTA no phase separation phase separationpressure build-up pressure build-up sour milk odor sour milk odor 0.10%Na Benzoate beginning of phase phase separation separation pressurebuild-up pressure build-up sour milk odor sour milk odor 0.025% Methylbeginning of phase beginning of phase separation Paraben separationpressure build-up 0.075% Propyl pressure build-up sour milk odor maskedby Paraben sour milk odor paraben odor 0.50% Lactic Acid phaseseparation phase separation pressure build-up pressure build-up sourmilk odor sour milk, rancid, off odor 1.00% Lactic Acid phase separationbeginning of phase separation pressure build-up pressure build-up sourmilk odor sour milk odor

TABLE 3.2 Preservative Test Results on Pancake Batter in Glass Vialswith 0.10% Sorbic Acid and 0.20% Potassium Sorbate After 170 Hrs.Additional Preservatives Air Headspace N₂ Headspace None beginning ofphase separation phase separation pressure build-up pressure build-upsour milk odor sour milk odor 200 ppm EDTA beginning of phase separationphase separation pressure build-up pressure build-up sour milk odor sourmilk odor 500 ppm EDTA no phase separation beginning of phase pressurebuild-up separation sour milk odor pressure build-up sour milk odor0.10% Na Benzoate beginning of phase separation phase separationpressure build-up pressure build-up sour milk odor sour milk odor 0.025%Methyl phase separation no phase separation Paraben pressure build-uppressure build-up 0.075% Propyl sour milk odor masked by sour milk odorParaben paraben odor masked by paraben odor 0.50% Lactic Acid phaseseparation phase separation pressure build-up pressure build-up sourmilk odor sour milk odor 1.00% Lactic Acid phase separation beginning ofphase pressure build-up separation no off odor pressure build-up sourmilk odor Note: Pressure build-up was characterized by an audiblepressure exhaust when the vial cap was unscrewed.

Example 4

Aim: to study the pressure build-up in pressurized and un-pressurizedcans.

Propellants: (i) None; (ii) CO₂; (iii) N₂. Fill: 8 oz. Hot process, 50°C. (120° F.) DI water+Elite Spice pancake mix. Preservative trials:

1. Un-pressurized crimped 205×604 3-pc steel, EP coated cans witha. 0.05% Sorbic Acid and 0.10% Potassium Sorbate combob. 0.05% Sorbic Acid and 0.10% Potassium Sorbate combo with N2 capc. 0.05% Sorbic Acid and 0.10% Potassium Sorbate combo+1.00% lactic acid(88%)d. 5% Sorbic Acid and 0.10% Potassium Sorbate combo+1.00% lactic acid(88%) with N2 cap2. Pressurized crimped 205×604 3-pc steel, EP coated cans witha. 1.0% Sorbates (combination of 0.40% Sorbic Acid and 0.60% PotassiumSorbate)b. a+200 ppm EDTAc. a+500 ppm EDTAd. a+0.1% Sodium Benzoatee. a+0.075% Propyl Paraben+0.025% Methyl Parabenf. a+0.5% Lactic Acid (88%)g. a+1.0% Lactic Acid (88%)

Results: There was a significant pressure build-up in bothun-pressurized samples (Dots—0.15% Sorbates, no N₂ Cap; HorizontalLines—0.15% Sorbates, 1.0% Lactic acid, no N₂ Cap) and N₂-pressurizedsamples (Vertical Lines—0.15% Sorbates, N₂ Cap; Black—0.15% Sorbates,1.0% Lactic acid, N₂ Cap) after 60 days. On the contrary,CO₂-pressurized samples dropped in pressure in the same time frame(Tables 4.1 and 4.2 and FIG. 3). The pressure build-up was morepronounced in the un-pressurized samples (FIG. 2; ˜40 psi average after60 days) than in the N₂-pressurized samples (˜13 psi average after 60days) (FIG. 4). And for the un-pressurized set, the samples withsorbates only (Dots—0.15% Sorbates, no N₂ Cap) result in more thandouble the final pressure compared to the sample with sorbates+lacticacid preservative system (Horizontal Lines—0.15% Sorbates, 1.0% Lacticacid, no N₂ Cap) (FIG. 2).

For the samples pressurized with CO₂ (Dots—1.0% Sorbates; VerticalLines—1.0% Sorbates, 200 ppm EDTA; Horizontal Lines—1.0% Sorbates, 500ppm EDTA; Diagonal Stripes LtoR—1.0% Sorbates, 0.1% Sodium benzoate;Black—1.0% Sorbates, 0.075% Propyl Paraben, 0.025% Methyl Paraben;Diagonal Stripes RtoL—1.0% Sorbates, 0.5% Lactic acid; White—1.0%Sorbates, 1.0% Lactic acid), the average pressure drop after 60 days wasabout 29 psi (FIG. 3)

As discussed in Example 3, the probable causes for the build up ofpressure in the un-pressurized and N₂ pressurized cans can have been (i)evolution of CO₂ from the bicarbonate leavening agent and/or (ii)microbial growth/fermentation.

In fermentation of sugars, one of the ingredients of the powder mix, thebyproducts are ethanol and CO₂. Some of the CO₂ is released to theheadspace of the can. However, a portion of the CO₂ is dissolved in thewater which, in effect, acidifies the batter. Additionally, othermicroorganisms such as lactic acid bacteria which can possibly bepresent in the mix (see Example 6), can produce acid byproducts such aslactic acid. Such byproducts can cause the batter to acidify. Thisacidification can then caused the sodium bicarbonate to release furtherCO₂.

The CO₂ due to microbial activity or bicarbonate decomposition in theun-pressurized cans produced the headspace pressure (FIG. 2). But whenthe headspace of the can already had a positive pressure as in the N₂pressurized samples (Dots—1.0% Sorbates; Vertical Lines—1.0% Sorbates,200 ppm EDTA; Horizontal Lines—1.0% Sorbates, 500 ppm EDTA; DiagonalStripes LtoR—1.0% Sorbates, 0.1% Sodium benzoate; Black—1.0% Sorbates,0.075% Propyl Paraben, 0.025% Methyl Paraben; Diagonal Stripes RtoL—1.0%Sorbates, 0.5% Lactic acid; White—1.0% Sorbates, 1.0% Lactic acid) (FIG.4), the production of CO₂ can have been restricted such that thepressure-build up was less than that in the un-pressurized samples.

On the other hand, un-pressurized and N₂-pressurized samples preservedwith sorbates combined with lactic acid had the least pressure build-up.And the more lactic acid added, the lower the pressure build-up (FIGS. 2and 4). Although the lactic acid efficacy cannot completely offset thebicarbonate decomposition due to acidity, it was significantly better asa preservative, in combination with sorbates, than the otherpreservative systems used.

The CO₂-pressurized cans exhibited reversed results and the pressuredecreased after 60 days (FIG. 3). One explanation is that some of theCO₂ molecules that were injected in the can were dissolved in the waterin the mix over time. This explains why the pressure decreased from theday the samples were made. The CO₂ generation in these samples cannothave been enough to overcome the amount of CO₂ dissolved in the sample.Therefore, the pressure effects of CO₂ dissolution were more evidentthan the effects of CO₂ generation. Alternatively, the CO₂ can havenatural anti-microbial action which impeded or slowed down microorganismgrowth. For fermentation, the CO₂ injected can have saturated the systemretarding further CO₂ production from yeast. For aerobic microorganisms,CO₂ made the environment undesirable for microbial growth.

TABLE 4.1 Pressure Build-up in Un-Pressurized Cans Can Pressure, psiPreservative System N₂ Cap 12 Hrs 48 Hrs 1440 Hrs 0.15% Sorbates no0.5-1.0 ~1.0 37 0.15% Sorbates yes ~1.0 ~1.0 42 0.15% Sorbates + 1.00%no ~1.0 ~2.0 16 Lactic Acid 0.15% Sorbates + 1.00% yes ~1.0 ~2.0 16Lactic Acid

TABLE 4.2 Pressure Changes in Pressurized Cans Pressure, psi 0 Hrs 72Hrs 1440 Hrs Preservative CO₂- N₂- CO₂- N₂- CO₂- N₂- System pressurized*pressurized* pressurized pressurized pressurized pressurized 1.0%Sorbates** 126 107 115 109 100  121 1.0% Sorbates + 120 105 111 106 96120 200 ppm EDTA 1.0% Sorbates + 118 112 109 112 87 126 500 ppm EDTA1.0% Sorbates + 122 107 112 107 93 122 0.10% Na Benzoate 1.0% Sorbates +122 107 112 107 89 120 0.075% Propyl Paraben + 0.025% Methyl Paraben1.0% Sorbates + 121 107 112 107 92 117 0.5% Lactic Acid 1.0% Sorbates +122 105 114 106  91** 111 1.0% Lactic Acid *Amount of propellant used:~3.30 g CO₂ and ~1.70 g N₂ **1.0% Sorbates is a combination of 0.4%Sorbic Acid and 0.6% Potassium Sorbate

Example 5

Aim: to study the pressure changes in the can pressurized with 50/50CO₂/N₂ as a follow-up to Example 4.

TABLE 5.1 Sample* Description for the Pressure Build-Up test on CansPressurized with 50/50 CO₂/N₂ Combo. Sample Code Formula PropellantFill, oz 06-023 Waffle formula (50/50 CO₂/N₂) 18 50.0% Water 2 g CO₂followed with 49.5% Elite Spice powder 2 g N₂ @ ~120 psi mix (lot2-27601) Total 4 g 0.5% Guardian CS1-50 (cultured dextrose) 06-024Pancake formula (50/50 CO₂/N₂) 18 52.5% Water 2 g CO₂ followed with47.0% Elite Spice powder 2 g N₂ @ ~120 psi mix (lot 2-27601) Total 4 g0.5% Guardian CS1-50 *Samples were stored at room temp for the durationof the study.

TABLE 5.2 Pressure Changes in Cans Pressurized with 50/50 CO₂/N₂ ComboSample Pressure, psi Code 2 Hrs 72 Hrs 264 Hrs 400 Hrs 1700 Hrs Pressure06-023 110 109 109 109 121 +11 06-024 109 108 107 107 118 +9 *For Time0, the pressure reading was taken ~2 to 3 hours after the samples weremade

Results: The pressure build up was similar to the N₂-pressurized samplesin Example 4 (see FIG. 4.6), but the amount of product in the cans wasincreased in this trial. Some of the injected CO₂ dissolved in the waterbut more CO₂ (or other gaseous microorganism byproducts) can begenerated, causing the pressure increase.

Example 6

Aim: to determine the shelf stability of the batter using trialpreservatives. The tests were conducted by BETA Food Consulting, Inc.

Mix: Pancake Batter: 47.5/52.7 Elite Spice Pancake Mix/DI Water. Screwcap glass vials. Primary Preservatives used: MG510 gassed with CO₂;CS1-50 gassed with CO₂; MG510 gassed with N₂; CS1-50 gassed with N₂.

TABLE 6.1 Parameters of the micro-study Batch 2 (Pancake) 47.5/52.5Batch 1 (Pancake) Elite Spice 50/50 Elite powder Spice powder mix/Watermix/Water Preservative (Cultured Microgard 510 (MG510) Guardian CS1-50Dextrose Maltodextrin) (lot# 510-425301) (lot# FS-102) PreservativeDosage 0.75% 0.50% Fill 18.3 oz 18.3 oz Can 214 × 804 214 × 804 Temp offinished batch 65° F. 55° F. Nitrogen cap no yes Codes V1, V3 V2, V4Inoculants: Y—yeast; LAB—lactic acid bacteria; SA—Staphilococcus Aureus;LM—Lysteria Monocytogenes; BC—Bacillus Cereus.

Results: Following is a study conducting a microbiological challenge onaerosolized food product. The pH of the aerosol food product isapproximately 6.0 and the water activity is 0.96. Growth of SelectedSpoilage and Pathogenic Organisms in an Aerosol Food Product

Purpose: The purpose of the study is to determine the fate of selectedspoilage and surrogates for pathogenic microbial agents when inoculatedinto an aerosolized food product. Outgrowth of lactic acid bacteria andListeria monocytogenes was problematic in a previous study completed inJanuary, 2006. For this reason, they will be the only organisms studiedon this formulation. A surrogate organism that is non-pathogenic will beused for L. monocytogenes to avoid the potential for contamination ofyour new facility. Listeria innocua will be used instead.

Product Variables: The product variables to be studied include: 1)MicroGard 510 with CO₂ (waffle); 2) MicroGard CS150 with CO₂ (waffle);3) MicroGard 510 with N₂ (pancake); and 4) MicroGard CS150 with N₂(pancake).

The intended shelf life is 45-60 days, minimum. No previous stabilityinformation had been gathered on the products. The study was continuedfor 105 days to determine whether a longer shelf life was possible.

Process: The pre-cooled batter was loaded into the cans after filling tominimize shifts in microbial loads. Empty cans were submerged in a 200ppm chlorine solution for a minimum of 60 seconds prior to draining andpermitting to air dry, for the purpose of disinfection. Cans werefilled, inoculated, capped with valve tops and pressurized, chilled inan ice bath, and immediately placed into refrigeration temperatures of40° C. (41° F.). Finished cans were stored for 1.5 days and transportedin a refrigerated truck.

Organisms: The organisms for challenge represented those of potentialsafety and spoilage concern. The only pathogen of potential concern thatwas not represented was C. botulinum. The test organism categoriesincluded: Bacillus cereus (gram positive spore former, thermo labiletoxin); Staphylococcus aureus (gram positive non-spore former, thermostable toxin); Listeria monocytogenes (gram positive non-spore former,psychrotroph); Zygosaccharomyces rouxii (yeast); Lactobacillusformentum; and Lactobacillus plantarum (combined inoculum of grampositive non-spore formers).

Culture Preparation: Lactic acid bacteria was grown in sterile MRSbroth. Other bacteria were grown in sterile trypticase soy broth. Yeastextract was added for the L. monocytogenes culture Bacteria werecultured for 24 hours at 35 C, then streaked on trypticase soy agar andincubated for 48 hours at 35° C. Yeast were cultured for 5 days at 24°C. on potato dextrose agar. Cell suspensions were prepared by harvestingcells into sterile 0.1% peptone water. Inoculum was adjusted to delivera target initial load of 103-104 cfu/g (minimum 590,000 cfu/can in each20 fl. oz. can). Inoculation was delivered with a 1 mL inoculum volume.The cans were inoculated in the ‘in-house’ R & D laboratory bench topcapping unit at Follmer Development, located away from the processingarea and not used for production. A Food Safety Solutions representativeconducted the inoculation.

Sixteen cans for each inoculum group were prepared. Two uninoculatedcontrols were additionally prepared for each of the 4 product variables.Swabs of the bench, utensils, and rinsate from the filler unit werecollected after cleaning and sanitization was complete to determineadequacy of cleaning. The unit was not be used before results wereavailable.

Test Method: Test methods for quantitation will be per FDA-BAM or AOAC.The changes in loads for each inoculum group will be measured at eachtest interval. Testing will be done in duplicate. Trend informationabout growth, death, or stasis will be available from the data.

Test Interval: Test intervals were spaced appropriately to represent the105 day storage period. Testing was conducted on inoculated variables 1,2, and 4 at day 2, 15, 30, 45, 60, 75, 90, and 105. Testing forinoculated variable 3 was conducted at day 2, 15, 30, and 45. Later testintervals for variable 3 were discontinued because inoculum loadssignificantly increased. Uninoculated controls were analyzed after 2 and105 for variables 1 and 2. An additional 45 day test interval was addedfor variables 3 and 4 to determine midpoint shifts in background floralevels.

Uninoculated control samples were analyzed for B. cereus, S. aureus, L.monocytogenes, lactic acid bacteria, yeast, mesophilic aerobic platecount, and mesophilic anaerobic spore former counts.

Storage Conditions: Products stored at 4° C. (40-41° F.).

The Pathogenic Organisms detected in the product after 2-105 days areshown in Tables 6.2-6.9.

TABLE 6.2 Inoculated Variable 1 - MicroGard 510 with C0₂ waffle B.cereus S. aurues L. monocytogenes Lactic acid bacteria Yeast AverageAverage Average Average Average Variable I Log10 Log10 Log10 Log10 Log10C02 (cfu/g) cfu/g (cfu/g) cfu/g (cfu/g) cfu/g (cfu/g) cfu/g (cfu/g)cfu/g Initial 1500 14000 8100 4900 8800 (Theoretical) Day 2 10003.0791812 9400 3.9542425 140000 4.93701611 1000 2.9542425 26000 Day 21400 8600 33000 800 24000 4.39794001 Day 15 900 2.8129134 5100 3.7363965190000 5.11058971 340 2.8864907 10000 4 Day 15 400 5800 68000 1200 10000Day 30 550 2.7520484 5000 3.744293 40000 4.34242268 95000 5.122215916000, 4.1903317 Day 30 580 6100 4000 170000 15000 Day 45 310 2.47712137200 3.6232493 63000 5.22141424 200000 5.0051805 12000 4.11394335 Day 45290 1200 270000 2400 14000 Day 60 160 2.3222193 1200 3.2671717 110004.31175366 25000000 7.5740313 2300 3.78887512 Day 60 260 2500 3000050000000 10000 Day 75 20 1.4771213 8000 4.1139434 500 3.82930377 8400007.5845574 5000 3.49831055 Day 75 40 18000 13000 76000000 1300 Day 90 2302.20412 200 2.2787536 22000 4.04336228 <10000 8.2787536 7200 3.6180481Day 90 90 180 100 190000000 1100 Day 105 340 2.469822 150 2.09691 380004.62324929 8000000 7.0791812 3900 3.56229286 Day 105 250 100 4600016000000 3400

TABLE 6.3 Inoculated Variable 2 - MicroGard CS150 with C0₂ waffle B.cereus S. aurues L. monocytogenes Lactic acid bacteria Yeast AverageAverage Average Average Average Variable 2 Log10 Log10 Log10 Log10 Log10C02 (cfu/g) cfu/g (cfu/g) cfu/g (cfu/g) cfu/g (cfu/g) cfu/g (cfu/g)cfu/g Initial 8800 (Theoretical) Day 2 500 2.845098 17000 4.023252527000 4.36172784 <100 2.30103 20000 4.21748394 Day 2 900 4100 19000 20013000 Day 15 600 2.6532125 9000 3.7596678 33000 4.56229286 100 2.14612811000 3.94939001 Day 15 400 2500 40000 180 6800 Day 30 430 2.61804812600 3.3891661 80000 4.66574174 2200 3.0569049 13000 4.06069784 Day 30400 2300 17000 80 10000 Day 45 240 2.39794 600 3 3617278 320000 569897120 3608526 8000 3.79239169 Day 45 260 4000 680000 8000 4400 Day 60 2902.5740313 2000 3.0700379 13000 4.42324587 <100 2 0 8000 3.6946052 Day 60460 350 40000 <100 1900 Day 75 210 2.4313638 2600 3.161368 290004.49136169 500 3.6283889 3500 3.41497335 Day 75 330 300 33000 8000 1700Day 90 390 2.6283889 100 3.0413927 27 52000 4.83250891 40 1.544068 3702.94694327 Day 90 460 2100 84000 30 1400 Day 105 390 2.5314789 8002.9542425 1100000 6.04139269 12000 3.8864907 4300 3_51851394 Day 105 2901000 1100000 3400 2300

TABLE 6.4 Inoculated Variable 3 - MicroGard 510 with N₂ ancake B. cereusS. aurues L. monocytogenes Lactic acid bacteria Yeast Average AverageAverage Average Average Variable 3 Log10 Log10 Log10 Log10 Log10 N2(cfu/g) cfu/g (cfu/g) cfu/g (cfu/g) cfu/g (cfu/g) cfu/g (cfu/g) cfu/gInitial 1500 14000 8100 4900 8800 (Theoretical) Day 2 1100 2.90309 94000 3.5965971 520000 5.6580114 1000 2.7781513 14000 4.07918125 Day 2500 3900 390000 200 10000 Day 15 900 2.8750613 5000 3.90309 28000006.62324929 330 2.6283689 23000 4.52504481 Day 15 600 11000 5600000 52044000 Day 30 480 2.607455 2300 3.50515 250000000 8.30103 110000 5.46239818000 4.23044892 Day 30 330 4100 150000000 470000 16000 Day 45 2202.3222193 2800 3.4771213 82000000 7.91645395 81000000 7.9566486 130004.09691001 Day 45 200 3200 83000000 100000000 12000

TABLE 6.5 Inoculated Variable 4 - MicroGard CS150 with N₂ (pancake) B.cereus S. aurues L. monocytogenes Lactic acid bacteria Yeast AverageAverage Average Average Average Variable 4 Log10 Log10 Log10 Log10 Log10N2 (cfu/g) cfu/g (cfu/g) cfu/g (cfu/g) cfu/g (cfu/g) cfu/g (cfu/g) cfu/gInitial 1500 14000 8100 4900 8800 (Theoretical) Day 2 500 2.7403627 65003.7853298 320000 5.35218252 <100 2 16000 4.38916608 Day 2 600 5600130000 100 33000 Day 15 500 2.6532125 5100 3.6627578 7600000 6.6857417480 1.9542425 22000 4.21748394 Day 15 400 4100 2100000 100 11000 Day 30600 2.7075702 3500 3.4313638 760000000 8.83569057 110 4.2318517 280004.41497335 Day 30 420 1900 610000000 34000 24000 Day 45 250 2.34242272700 3.1903317 100000000 8.04139269 1900 3.3710679 18000 4.30103 Day 45190 400 120000000 2800 22000 Day 60 260 2.5314789 3300 3.752048430000000 7.60205999 150000 5.2671717 22000 4.26717173 Day 60 420 800050000000 220000 15000 Day 75 340 2.5118834 3200 3.3617278 70000006.87506126 2000000 6.062582 4800 3.44715803 Day 75 310 1400 8000000310000 800 Day 90 380 2.5185139 28000 4.2900346 4800000 6.85733251200000 5.845098 7200 3.8920946 Day 90 280 11000 9600000 200000 8400 Day105 250 2.3222193 160000 5.2304489 2300000 6.31175386 2500000008.4771213 2400 3.98677173 Day 105 170 180000 1800000 350000000 17000

TABLE 6.6 Uninoculated Control Variable I - MicroGard 510 with C0₂waffle Mesophilic anaerobic Lactic acid Aerobic Anaerobic sporeformerVariable 1 B. cereus S. aureus L. moncyfogenes bacteria Yeast platecount plate count plate count Control (cfu/g) (cfu/g) (cfu/g) (cfu/g)(cfu/g) (cfu/g) (cfu/g) (cfu/g) Day 2 <10 <10 <10 <10 <10 210 <10 140Day 2 <10 <10 <10 <10 <10 310 <10 200 Day 105 <10 <10 <10 280000000 <10160000000 170000000 <10 Day 105 <10 <10 <10 150000000 <10 840000010000000 <10 Sample aroma at 105 day interval was acceptable.

TABLE 6.7 Uninoculated Control Variable 2 - MicroGard CS150 with C0₂waffle Mesophilic Aerobic anaerobic Lactic acid plate Anaerobicsporeformer Variable 2 B. cereus S. aureus L. moncytogenes bacteriacount plate count plate count Control (cfu/g) (cfu/g) (cfu/g) (cfu/g)Yeast (cfu/g) (cfu/g) (cfu/g) (cfu/g) Day 2 <10 <10 <10 <10 <10 110 <10150 Day 2 <10 <10 <10 <10 <10 290 <10 120 Day 105 <10 <10 <10 40000 <101100 45000 <10 Day 105 <10 <10 <10 34000 <10 2000 50000 <10 Sample aromaat 105 day interval was acceptable.

TABLE 6.8 Uninoculated Control Variable 3 - MicroGard 510 with N₂pancake Mesophilic anaerobic Lactic acid Aerobic Anaerobic sporeVariable 3 B. cereus S. aureus L. moncytogenes bacteria plate countplate count count Control (cfu/g) (cfu/g) (cfu/g) (cfu/g) Yeast (cfu/g)(cfu/g) (cfu/g) (cfu/q) Day 2 <10 <10 <10 <10 <10 390 <10 140 Day 2 <10<10 <10 <10 <10 310 <10 170 Day 45 <10 <10 <10 2500000 <10 28000 300000<10 Day 45 <10 <10 <10 2000000 <10 45000 400000 <10 Day 105 <10 <10 <10560000000 <10 280000000 560000000 <10 Day 105 <10 <10 <10 390000000 <10500000000 390000000 <10 Sample aroma at 105 day interval wasunacceptable (putrid).

TABLE 6.9 Uninoculated Control Variable 4 - MicroGard CS150 with N₂pancake Mesophilic Lactic acid Aerobic Anaerobic anaerobic Variable 4 B.cerous S. aureus L. moncytogenes bacteria plate count plate count sporecount Control (cfu/g) (cfu/g) (cfu/g) (cfu/g) Yeast (cfu/g) (cfu/g)(cfu/g) (cfu/g) Day 2 <10 <10 <10 <10 <10 150 <10 130 Day 2 <10 <10 <10<10 <10 350 <10 130 Day 46 <10 <10 <10 39000 100 1000000 1500000 <10 Day45 <10 <10 <10 34000 150 550000 910000 <10 Day 105 <10 <10 <10 1600000020 17000000 18000000 <10 Day 105 <10 <10 <10 80000000 100 8000000052000000 <10

At day 15, no appreciable changes in inoculum loads were observed, withthe exception of L. monocytogenes in variables 3 and 4. A small (1 log10) increase occurred between 2 and 15 days. All sample variable resultsremained acceptable.

At day 30, variable 1 experienced an approximate 2 log₁₀ increase inlactic acid bacteria levels since the last interval (Day 15). All otherresults did not appreciably change. The net increase in lactic acidbacteria from the initial inoculum levels was about 2 logs, which wasstill considered acceptable. Variable 2 similarly experienced anincrease in lactic acid bacteria, but only by approximately 1 log₁₀ .Listeria monocytogenes and lactic acid bacteria exhibited spikes(approximately 2 log) in counts in variables 3 and 4 (packaged innitrogen). In order to determine whether the cause was related tobackground flora activity, the decision was made to test theuninoculated controls at the next test interval (Day 45). All resultswere considered acceptable after 30 days storage.

After 45 days storage, variable 1 sustained an approximate 2 log overallincrease in lactic acid bacteria levels, with 45 day average loads of5.0 log₁₀. The changes in populations were not unacceptable. Variable 2experienced a 1 log increase in L. monocytogenes and sustained a 2 logincrease in lactic acid bacteria loads. Overall results were acceptableafter 45 days storage. Variable 3 experienced an increase ofapproximately 5 logs in lactic acid bacteria since Day 2, which wasconsidered unacceptable. Listeria monocytogenes increased by 2-3 log₁₀since initially inoculated. Counts in inoculated samples for Variable 4did not change appreciably since the last interval (Day 30).Uninoculated control lactic acid bacteria levels were higher inuninoculated control variable 4 than in sample inoculated with lactics,reflecting that previous withdrawal of product from the container(uninoculated control) likely caused elevated counts due to fouling ofthe nozzle, not changes in the internal product itself. Since theresults for Variable 3 were poor, testing of the inoculated sample wasdiscontinued. Testing of the uninoculated control was continued, as forother controls. Testing for Variables 1, 2, and 4 were continued, asscheduled.

After 60 days of storage, a 2.5 and 2.0 log_(in) increases in lacticacid bacteria levels were observed in variables 1 and 4, respectively.Results were not indicative of a product failure. No other appreciablechanges in microbial loads were observed.

No appreciable changes occurred in microbial loads between 60 and 75days storage.

After 90 days storage, 0.5 log lactic acid bacteria increase wasobserved in variable 1. No other changes occurred.

Between 90 and 105 days of storage, L. monocytogenes increased by 1log₁₀ in variable 2 and lactic acid bacteria increased by more than 2log₁₀ . Staphylococcus aureus increased by approximately 1 log₁₀ withinthe same timeframe.

None of the uninoculated controls had detectable pathogens isolated fromthem over the 105 day storage period.

Chief flora associated with uninoculated controls were lactic acidbacteria. Mesophilic anaerobic spore former counts did not change duringthe 105 storage period, indicating no need to conduct a follow-up C.botulinum inoculation study.

Aroma defects observed in uninoculated controls after 105 days storagewere associated with variables 3 and 4, which had higher loads. Lacticacid bacteria, aerobic plate counts, and anaerobic plate counts in thevariables with N₂ used as a propellant were extremely high. In thecontrol variables containing C0₂ as a propellant, aroma defects were notobserved after 105 days storage. Indicator microbe loads were alsomarkedly lower in those variables (1 and 2).

The sum of observation results for aroma indicates the organolepticendpoint for variables 1 and 2 was beyond 105 days and for variables 3and 4 it was less than 105 days. The apparent microbiological endpointsare discussed below.

None of the variables supported outgrowth of toxigenic pathogens overthe 105 day storage period (S. auneus, B _(—) cereus). Variables with N₂propellant permitted faster outgrowth of L. monocytogenes, to higherlevels. Use of C0₂ as a propellant appears to suppress Listeria growth,reducing risk of hazard from end-user under cooking.

Overall, the formulation for Variable 2, containing MicroGard CS150 withC0₂ (waffle), was most stable against spoilage organisms (uninoculatedcontrols) and L. monocytogenes (inoculated samples). Spoilage bacteriallevels never exceeded 104 cfu/g during the 105 day storage period inuninoculated controls. The marked spike (approximately 2 log₁₀) between90 days and 105 days in L. monocytogenes levels for the inoculatedsample variable 2 reflect the microbiological endpoint for variable 2could conservatively be set at 90 days.

The spike in lactic acid bacteria (2.5 log₁₀) between 45 and 60 days forvariable 1 indicates stability begins to decline. Since the organolepticendpoint (uninoculated control) was beyond 105 days, a conservativeendpoint for variable 1 could be set at 60 days.

The microbiological shelf life endpoint for inoculated variable 3 was 30days, based on marked changes in lactic acid bacteria levels after thattime.

The aroma for uninoculated variable 4 was objectionable after 105 daysstorage. The endpoint would have been sooner, but was not determined.Based on the microbiological results, a conservative endpoint for thelactic acid bacteria might be 60-75 days, based on substantial increasesat those intervals.

A mix of propellant gases (N₂ and C0₂) would likely result in betterstability than N₂ alone

The resident organism in the batter using Elite Spice Pancake Mix islactic acid bacteria. This organism is not pathogenic and the onlyconcern is aroma defect when present in high loads.

Based on the data, Variable #2 (CS150 gassed with CO₂) was the moststable against spoilage organisms. None of the variables supportedoutgrowth of toxigenic pathogens over the 105 day storage period (S.aureus, B. cereus). Variables with N₂ propellant permitted fasteroutgrowth of L. monocytogenes, to higher levels but the use of CO₂ as apropellant appears to suppress Listeria growth, reducing risk of hazardfrom end-user under baking the product while cooking.

Example 7

Aim: to monitor the weight losses in samples

The samples tested were pancake and waffle formulations with the pancakegassed with 3.5 g gas (30% CO₂ and 70% N₂) and the waffle gassed with7.0 g CO₂. All the samples were in 214×804 cans. The samples were keptat room temperature throughout the test.

TABLE 7.1 Age of Samples Tested for Example 7 Out of the refrigeratorAge, Description Prepared Date days 05-167 waffle formula with 7.0 gSep. 29, 2005 Mar. 1, 2006 153 CO₂ 05-203 waffle formula with 7.0 g Dec.14, 2005 Mar. 1, 2006 77 CO₂ 06-017 pan cake formula Feb. 16, 2006 Mar.1, 2006 13 with 3.5 g gas (30% CO₂ and 70% N₂) 06-018 pan cake formulaFeb. 16, 2006 Mar. 1, 2006 13 with 3.5 g gas (30% CO₂ and 70% N₂)

TABLE 7.2 Weight Monitoring of Pancake and Waffle Aerosol Cans Weight,grams Day 0 2 5 9 13 Weight 05-167 642.0 641.9 641.8 641.5 641.5 −0.505-203 643.8 643.8 643.8 643.7 643.7 −0.1 06-017 637.6 637.6 637.5 637.6637.5 −0.1 06-018 636.6 636.6 636.5 636.5 636.5 −0.1

Results: After 13 days, there was no significant weight loss (or leak)from the can. The weight loss observed can have been due to leakage ofgas when pressure readings were taken. The packaged batter does not poseany leaking problem. The valve, crimp and can specifications areappropriate for use in this application.

Example 8

Aim: to determine the density of the batters

Formula: 47.5 powder mix/52.5 water; Cold process (water temperature is50° F.; finished batter is 61° F.); Preservatives: 0.05% Sorbic Acid and0.10% Potassium Sorbate combo; Graduated cylinder method.

Results: Calculated density: 1.33 g/mL at ˜16° C. (61° F.). Thesuspended solids made the product denser. A cold process is moreappropriate for the batter preparation. Higher temperature will causethe sodium bicarbonate to decompose and the leavening effect lost.

Example 9

Aim: to determine the effect of mixing time on the viscosity of thebatter.

Formula: 50/50 Elite Spice Pancake Mix 18636AO/Water. Viscositymeasurements were taken throughout the mixing time of the batter. Theviscometer used was Brookfield DV-II+ viscometer

TABLE 9.1 Effect of Time of Mixing to the Viscosity of the Batter Time,mins Viscosity, cP* Temperature, ° F. 2 15,000 60.0 4 16,000 6 15,000 814,500 10 13,500 61.3 12 13,300 14 12,750 63.0 Mixing stopped at 14mins. Batter was stored at ~4± ° C. (40° F.) for 15 minutes. Timer isrestarted 0 17,000 53.0 30 15,600 60.5 60 15,200 64.5 *RV Spindle #6 at20 rpm, 1 minute

Results: The data show that the batter exhibits a non-Newtonian propertywhich is thixotropic. As a result, shear (mixing) decreases theviscosity but recovers its original viscosity after the applied shear isreduced or removed. Accordingly, extended mixing of the batter toachieve homogeneity during process cannot be detrimental to the finalmix.

Example 10

Aim: to determine delivery weight of batter in pressurized container.

Fill: 22 oz; Pressure: 130 psi (2.6 g N2); Can: 214×804; Valve: S633×022″ Summit Whipped Cream Valve (Summit)+Whipped Cream Actuator; thespray-out was not intermittent.

Results: Total delivery weight from a 22 oz filled 214×804 can isapproximately 18 oz. Spraying the product out of the can at once leavesapproximately 18% in the can. This high retention weight is due to theviscosity of the batter. The flow of the product is slow and has thetendency to cling to the sides of the can. The propellant is exhaustedeven before most of the product is expelled from the can.

Example 11

Aim: to determine the delivery weight of batter from a 211×713 can befilled at 18 oz.

Formula: Waffle (50/50 Elite Spice Pancake Mix/Water); Can: 211×713,3-piece Valve: S63 3×0.022″ (tilt action) (Summit) Whipped CreamValves+Whipped Cream Actuator; fill: 18 oz; Propellant: 3 g (50/50CO₂/N₂); Order of gassing: CO₂ first to achieve 1.5 g, then N₂ withregulator set at 140 psi. At this pressure, 1.5 g N₂ is injected in thecan; Storage: Refrigerator at 4±2° C. (40±2° F.) for 2 days.

The product was dispensed while cold until gas starts to come out of thenozzle. The can was shaken to dispense more product.

TABLE 11.1 Delivery Weight of an 18 oz Batter Filled 211 × 713 CanAmount Delivered, g Condition 316 Gas comes out for the first time 434After shaking; more product was dispensed until gas came out. 440 Whenconsumer is likely to stop trying to dispense more product

Total delivery weight from an 18 oz filled 211×713 can is approximately440 g or 15.5 oz. Retention weight is approximately 2.5 oz.

Results: Contrary to the procedure carried out in Example 10, thedelivery was maximized by shaking the can, the retention is stillapproximately 13%. This is due to the viscous characteristic of thebatter (as discussed in Example 10).

Example 12

Aim: to determine the delivery weight of Batter from a 211×713 can witha S63 3×0.030″ tilt action valve filled with 23 oz high water ratiobatter.

Base formula: 40/60 Elite Spice Pancake Mix 18636A0/Water; Fill: 23 ozin 214×804 3-piece can; Valve: S63 3×0.030″ tilt action valve+WhippedCream Actuator (Summit)

Propellant: (i) Pancake is gassed with ˜2.2 g (50/50 CO₂/N₂); Order ofgassing: CO2 first to achieve 1.1 g, then N₂ with regulator set at 125psi. At this pressure, 1.1 N₂ is injected in the can; (ii) Waffle isgassed with 4.3 g CO₂ with the regulator set at 170 psi.

TABLE 12.1 Delivery Weight of High Water Ratio Batter in a Can with aS63 3 × 0.030″ Valve Filled at 23 oz Delivery weight, g % DeliveredPancake 20.9 90.9 Waffle 19.8 86.1

Results: Less viscous batter flowed better inside the can such that moreproduct is expelled before the propellant is exhausted. This in effectincreased the product yield from the can.

Example 13

Aim: to determine the spray rate of product using different valves.

Can: 214×804, 3-piece; Fill: 18 oz

Valves Tested: (i) SV-77/HF 2×0.035″×0.090″ (vertical action)(Summit)+Whipped Cream Actuator; (ii) S63 3×0.030″(tilt action) WhippedCream Valve (Summit)+Whipped Cream Actuator; (iii) S63 3×0.022″ (tiltaction) Whipped Cream Valve (Summit)+Whipped Cream Actuator.

Formulas: (i) for Valve 1, Waffle (50/50 Elite Spice Pancake Mix/Water)with 0.75% Microgard MG510; (ii) for Valve 2, Sample Code 06-159, 40/60Elite Spice Pancake Mix 18636A0/Water; for Valve 3, Waffle (50/50 EliteSpice Pancake Mix/Water) with 0.75% Microgard MG510.

Propellant: (i) for Valve 1, 4 g (50/50 CO₂/N₂); Order of gassing: CO₂first to achieve 2 g, then N₂ with regulator set at 125 psi. At thispressure, 2 g N₂ is injected in the can; (ii) for Valve 2, approximately7.0 g CO₂; regulator pressure set at 170 psi; (iii) for Valve 3, 4 g(50/50 CO₂/N₂); Order of gassing: CO₂ first to achieve 2 g, then N₂ withregulator set at 125 psi. At this pressure, 2 g N₂ is injected in thecan.

Storage: Refrigerator at 4±2° C. (40±2° F.) for 3 days. Spray rates weretaken at 10 seconds per spray.

TABLE 13.1 Spray Rate of Waffle batter (i) Using the Valve SV-77/HF 2 ×0.035″ × 0.090″ (vertical action) (Summit) Spray Rate, g/s First spray21.7 Second spray* 21.2 The delivery weight for this sample is 12.5 oz***Second spray lasted for only 6.5 seconds until air started to come out.**The delivery rate was not maximized. More product could be yielded byshaking the can. This was not done in this trial.

TABLE 13.2 Spray Rate of Waffle batter (ii) Using the Valve S633 ×0.030″ (tilt action) whipped cream valve (Summit) Spray Rate, g/s Firstspray 16.1

TABLE 13.3 Spray Rate of Waffle batter (ii) Using the Valve S63 3 ×0.022″ (tilt action) Whipped Cream Valve (Summit) Spray Rate, g/s Firstspray 9.2 Second spray 7.6 Third spray 6.7 Fourth spray 6.0 Fifthspray*** 6.7 Sixth spray**** 6.1 The delivery weight for this sample is13.6 oz***** **Fifth spray was 10 mins apart from the fourth spray whilethe can is left at room temperature. ***Sixth spray was 10 mins apartfrom the fifth spray while the can is left at room temperature. Sixthspray lasted for only 5 seconds until air started to come out. *****Asin Table 13.1, the delivery rate was not maximized. More product couldbe yielded by shaking the can. This was not done in this trial.

Results: The wide open valve SV-77/HF 2×0.035″×0.090″ (Table 13.1)delivered a faster spray rate but yielded only 12.5 oz of product(although this amount was not maximized by shaking the can). The sprayrate through the valve overcame the product flow inside the can. Thevalve S63 3×0.022″ (Table 13.3) had a smaller orifice therefore having aslower spray rate but yielding around 1 oz more in delivery weight (alsonot maximized). The valve with slightly wider the orifice size to3×0.030″ (Table 13.2) delivered a faster spray rate. This test only hadone data point and no other parameters were tested.

Example 14

Aim: to set the filling parameters of products using the gasser-crimper.

Pancake and waffle products were filled at different fill weights andran through the gasser-crimper (Terco, Inc.) varying gassing pressureand time and crimping pressure. The valves used were: (i) S63 3×0.030″Tilt Action Valve+Whipped Cream Actuator (Summit); (ii) 34002×0.045″×0.037″ Whipped Cream Valve and Actuator (Clayton); (iii) 5477Unrestricted Flow Whipped Cream Valve and Actuator (Clayton).

TABLE 14.1 Gasser-Crimper Data for Pancake batter (High Fill) Gassedwith CO₂ at 150 psi for 2 to 4 seconds with a Crimper Pressure of About100 psi Initial Pressure Results and Fill, CO₂ Gassing pressure, after 1Spray rates, Sample # oz Valve injected, g time, sec psi day, psi g/s 0123.0 3400 3.2 2 02 22.6 3400 3.4 2 03 22.5 S63 3 × 0.030″ 3.5 2 98 627.46 (shaken) 04 22.6 S63 3 × 0.030″ 3.4 2 90 (not shaken) 05 22.3 S63 3× 0.030″ 3.6 2 06 22.3 S63 3 × 0.030″ 3.9 4 106 07 22.3 S63 3 × 0.030″3.9 4 08 21.8 S63 3 × 0.030″ 3.6 2 09 21.7 S63 3 × 0.030″ 3.6 2 10 22.2S63 3 × 0.030″ 5.0 (Manual) 10.8 (refrigerated) 11 22.2 S63 3 × 0.030″7.0 (Manual) 13.0 (not refrigerated)

TABLE 14.2 Gasser-Crimper Data for Waffle batter (Various Fill Weights)with S63 3 × 0.030″ Whipped Cream Valve (Summit) Gassed with CO₂ at 150psi for 4 seconds with a Crimper Pressure of About 110 psi Spray InitialFollowing rates, g/s, Sam- Fill, CO₂ pressure, pressure and other ple #oz injected, g psi data, psi Results 12 18.0 5.9 13 18.0 5.8 125 106 (6days) 14 18.0 5.4 Average: 5.7 15 19.0 5.1 16 19.0 5.2 120 17 19.0 5.318 19.0 5.2 12.75 (after 5 days) Average: 5.2 19 20.0 5.0 125 111(overnight) Retention shaken to 68 weight: 1.3 oz 20 20.0 5.0 21 20.05.0 22 20.0 5.1 23 20.0 5.0 Average: 5.0 24 17.6* 6.0 25 21.0 4.6 2621.0 4.7 Average: 4.6

TABLE 14.3 Gasser-Crimper Data for 20 oz Waffle with 3400 Clayton ValveGassed with CO₂ at 150 psi for 2 to 4 seconds with a Crimper Pressure ofAbout 115 psi CO₂ Gassing Sample # Fill, oz injected, g time, sec Sprayrates, g/s 27 20.0 4.9 4 shaken: 22.0, 21.7 overnight: 12.5 28 20.0 5.14 overnight: 18.0 29 20.0 4.9 4 30 20.0 4.7 2 shaken, overnight: 13.0Average: 4.9

TABLE 14.4 Gasser-Crimper Data for 20 oz Waffle batter with 5477 ClaytonValve Gassed with CO₂ at 150 psi for 2 seconds with a Crimper Pressureof About 115 psi Sample # Fill, oz CO₂ injected, g Spray rates, g/s 3120.0 5.3 28.0 32 20.0 5.2 33 20.0 5.1 34 20.0 5.2 35 20.0 5.3 36 20.05.2 37 20.0 5.2 38 20.0 5.2 39 20.0 5.3 40 20.0 5.3 Average: 5.2

Results: As the fill weight of the product is reduced, the more gas isaccommodated in the can (Tables 14.1 and 14.2). The gassing capabilityof the plant maxes at around 5.2 g CO₂ for can filled with 20 oz ofbatter. The desired fast/high delivery weight is achievable by using ahigh flow valve such as Clayton's 5477 (Table 14.4).

The mechanism of the gasser-crimper depends highly on the pressure ofthe propellant injected, the length of time of gassing, the headspace inthe can available for the propellant, and the crimping pressure. Some ofthese parameters were varied and the results were very conclusive.

CO₂ Pressure: Due to the gasser-crimper's limitation, the CO₂ injectionpressure was maxed at 150 psi to introduce the maximum amount of CO₂into the headspace of the batter.

Length of Time of Gassing: This parameter was varied from 2 to 4seconds. As the point of entry of the gas is through the wide-open1-inch mouth of the can, there was no restriction in gassing andextending the length of time of gassing hardly increased the amount ofCO₂ injected (Tables 14.1 and 14.3)

Headspace of the Can: In any can, the lesser the product contained inthe can, the higher the headspace available. For the 214×804 can,filling the can with 18 oz of batter leaves about 400 mL headspace andfilling it with 20 oz reduced the headspace by about 10% (355 ml). Thisis why 18 oz filled cans can hold about 5.7 g CO₂ while 20 oz filledcans can hold about 5.0 g CO₂ (Table 14.2)

Crimping Pressure: This is the pressure that counters the CO₂ or gassingpressure. Increasing the crimping pressure will prevent some of the CO₂already situated in the headspace of the can from escaping. If thispressure is lower, some of the CO2 will evacuate the headspace until thecountering crimp pressure is able to descend and fasten the valve on thecan. (See Table 14.2 20 oz and table 14.4).

Example 15

It was observed that a sample gassed with CO₂ was also suitable to makelight and fluffy pancakes. Previously (see Example 1) it was observedthat the dissolved CO₂ escaped the batter during the cooking processmaking the pancakes flat and thin. Previously, the sample gassed with N₂made better pancakes than the one gassed with CO₂. The N₂ pressurizedthe can, but did not really get absorbed or mixed in the water/batter.The batter dispensed was therefore denser and made thicker, sponge-likepancakes similar in appearance and texture to normal pancakes. Bychanging the recipe, including the water to powder ratio (43% water byweight) and charging the can with more carbon dioxide (5.5 g) it hasbeen possible to obtain light and fluffy pancakes and light and crispywaffles with the same mix. The test candidate preferred the light andfluffy pancakes over the denser pancakes made with the nitrogen filledcan and the older mix.

Process Parameters: Product was prepared as shown in Table 15.1. Productwas stored at under 4° C. (40° F.). Sampling occurred everyday for 14days. On the 13^(th) day the product had a sour taste, off flavor, odorand a foamy texture. Product was prepared as shown in Table 15.2.Product was stored at under 4° C. (40° F.). Sampling occurred everydayfor 14 days. On the 119^(th) day the product did not have a sour taste,off flavor, odor and a foamy texture.

Conclusion: the temperature that the samples that were packed atmaterially affects the integrity of the product when stored for longdurations at below 40° F. We speculate that the cold processing inhibitsthe transfer and or growth of bacteria prior to packaging in the cans.

TABLE 15.1 Process Preparation for integrity of storage study WafflePancake Mixing Amount 523.91 lbs 523.91 lbs Mixing Process Mixed in a 60gal tank with a two Mixed in a 60 gal tank with a two blade mixer(manually varied blade mixer (manually varied height before circulatingpump height before circulating pump was set up) was set up) Additionalmixing with a lab- Additional mixing with a lab- mixer (hand held) mixer(hand held) Circulating pump Circulating pump Mixing Time Addition ofingredients (while Total mixing time including mixing): 60 mins additionof ingredients while Mixing (without circulating mixing and whilecirculating pump): 30 mins pump is on: 180 minutes Stand-by time (pumpinstallation): 30 mins Circulating pump: 60 mins TOTAL: 180 minutesSequence of addition of Water Water ingredients Powder Mix (dried wholeegg, Powder Mix (dried whole egg, soybean powder, sodium soybean powder,sodium bicarbonate, salt, cultured bicarbonate, salt, cultured dextrosemaltodextrin, dicalcium dextrose maltodextrin, dicalcium phosphate,xantham gum) phosphate, xantham gum) Sugar Sugar Wheat flour Wheat flourMixing temperature 70° F. 70° F. Finished batch temperature 70° F. 75°F. Filling Fill 20 oz 20 oz CO weight 5.2 g average 5.4 g average CanPressure ~130 (start) ~130 (start) ~115 (overnight, no shaking) ~115(overnight, no shaking)

TABLE 15.2 Cold Process Preparation for integrity of storage studyWaffle Pancake Mixing Amount 523.91 lbs 523.91 lbs Mixing Process Mixedin a 60 gal tank with a two Mixed in a 60 gal tank with a two blademixer (manually varied blade mixer (manually varied height beforecirculating pump height before circulating pump was set up) was set up)Additional mixing with a lab- Additional mixing with a lab- mixer (handheld) mixer (hand held) Circulating pump Circulating pump Mixing TimeAddition of ingredients (while Total mixing time including mixing): 60mins addition of ingredients while Mixing (without circulating mixingand while circulating pump): 30 mins pump is on: 180 minutes Stand-bytime (pump installation): 30 mins Circulating pump: 60 mins TOTAL: 180minutes Sequence of addition of Water Water ingredients Powder Mix(dried whole egg, Powder Mix (dried whole egg, soybean powder, sodiumsoybean powder, sodium bicarbonate, salt, sodium lactate, bicarbonate,salt, sodium lactate, dicalcium phosphate, rice bran) dicalciumphosphate, rice bran) Sugar Sugar Wheat flour Wheat flour Mixingtemperature 39° F. 39° F. Finished batch temperature 40° F. 40° F.Filling Fill 20 oz 20 oz CO weight 5.2 g average 5.4 g average CanPressure ~130 (start) ~130 (start) ~115 (overnight, no shaking) ~115(overnight, no shaking)

Example 16 Growth of Selected Spoilage and Pathogenic Organisms in anAerosol Food Product

Product was prepared as shown in Table 16.1. Product was stored at under4° C. (40° F.). 20 oz. Cans 567.0 g product and 5.5 g CO₂. Report fromBETA Food Consulting, Inc.

Following is a study conducting a microbiological challenge study on therevised formula of the aerosolized food product (Table 16.1). The pH ofthe aerosol food product is approximately 6.57.5 and the water activityis 0.96.

Purposes: The purpose of the study is to determine the fate of selectedspoilage and surrogates for pathogenic microbial agents when inoculatedinto an aerosolized food product. Outgrowth of lactic acid bacteria andListeria monocytogenes was problematic in Example 4. For this reason,these organisms are studied in this formulation. A surrogate organism(Listeria innocua) that is non-pathogenic will be used instead of L.monocytogenes to avoid potential contamination of facility.

Product Variable: The product to be studied is given in Table 16.1; thevariable addressed is the use of sodium lactate with CO₂.

The intended shelf life is 45-60 days, minimum The study will assessstability for as long as 120 days.

Process: The batter temperature is 7° C. (45° F.) or below at the timeof filling the cans. Empty cans will be disinfected per the processset-up, with chlorine at 50-200 ppm. Filled cans will be removed fromthe line before installation of the gas valves. They will immediately betransported to the in-house laboratory for inoculation, before havingthe valve tops installed and gas applied. Finished cans will be storedand transported to Food Microbiological Laboratories by Follmer in arefrigerated truck.

Organisms: The organisms for challenge should represent those ofpotential safety and spoilage concern, as demonstrated in the previousstudy. No mesophilic spore former activity was noted in the previousstudy, indicating C. botulinum should not be problematic.

The test organism categories will include:

1. Listeria innocua (non-pathogenic surrogate organism for L.monocytogenes (gram positive non-spore former, psychrotroph).2. Lactobacillus fermentum, Lactobacillus plantarum (combined inoculumof gram positive non-spore formers).

Culture Preparation: Lactic acid bacteria will be grown as a lawn onsterile MRS agar. Listeria innocua will be grown on sterile trypticasesoy agar with yeast extract. Bacteria will be cultured for 24 hours at35° C., then streaked again on trypticase soy agar and incubated for 48hours at 35° C. The cells will be prepared by harvesting cells intosterile 0.1% peptone water.

Inoculum will be adjusted to deliver a target initial load of 103-104cfu/g (minimum 590,000 cfulcan in each 20 fl. oz. can). Inoculation willbe delivered with a 1 ml inoculum volume. The cans will be inoculated inthe in-house laboratory at Follmer Development on the R & D laboratorybench top capping unit that is remote from the processing area and notused for production. A Food Safety Solutions representative will assistwith inoculation at the facility in Thousand Oaks, Calif.

Sixteen cans for each inoculum group will need to be prepared. SixteenUninoculated control cans are also necessary. The customer will beresponsible for adequate cleaning and sanitization of the bench topfilling unit. Swabs of the bench, utensils, and rinsate from the valveapplication and gas charging unit will be collected after cleaning andsanitization is complete—The unit should not be used before resultsreflect inoculum organisms have been adequately ridded

Test Method: Test methods for quantitation will be per FDA-BAM or AOAC.The changes in loads for each inoculum group will be measured at eachtest interval. Testing will be done in duplicate. Trend informationabout growth, death, or stasis will be available from the data

Test Interval: Test intervals will be spaced appropriately to representa 120 day storage period. Testing will be conducted on inoculatedvariables at day 2, 30, 45, 60, 75, 90, 105 and 120. Uninoculatedcontrols will be analyzed at 2, 45, 60, 75, 90, 105 and 120.

Uninoculated control samples will be analyzed to determine backgroundspoilage flora response, and also for absence of Listeria innocua. Theywill be analyzed for L. innocua, lactic acid bacteria, yeast, mesophilicaerobic plate count, and mesophilic anaerobic spore former counts.

Storage Conditions: Products will be stored at 4° C. (40-41° F.).

Product: The constituents of the Product to be tested are shown in Table16.1.

TABLE 16.1 Product Constituents Ingredients Batch % Target Batch #Equiv. Wt. g Water 40.3609% 8.88 4036-090 Wheat Flour 34.3302% 7.603453.020 (white, all-purpose, enriched, unbleached) Sugars. Granulated12.3860% 2.72 1238.600 Egg, Whole, Dried 2.6075% 0.57365 260.750 OrganicSoybean Powder 1.5645% 034419 156.45000 Bakeshire 187 (Sodium 1.1734%0.26 117.340 Bicarbonate) Salt 0.6519% 0-14 63.190 SL.-75A Sodium3.0000% 0.66000 300.000 Lactate (60%) Dicalcium Phosphate 3.5100%0.77220 351.000 Dihydrate Ribus Nu-bake 0.1956% 0.04303 19.360 TOTALS:100.0000% 22.00 10000.00

The Pathogenic Organisms detected in a product spiked with the organismand tested after a given number of days is shown in Table 16.2. ThePathogenic Organisms detected in a control sample not spiked with theorganism and tested after a given number of days is shown in Table 16.3.

TABLE 16.2 Pathogenic Organisms detected in spiked product Sodiumlactate w/CO₂ L. Innocua Lactic acid bacteria Test Average Averageinterval (cfu/g) Log₁₀ cfu/g (cfu/g) Log₁₀ cfu/g Initial 30000 170000(Theoretical) Day 2 2600 3.38916608 7600 3.81291336 Day 2 2300 5400 Day30 830 3.04758468 Day 30 1500

TABLE 16.3 Pathogenic Organisms detected in unspiked product MesophilicLactic acid Aerobic anaerobic Variable 1 Listeria bacteria plate countspore former Control genus/25 g) (cfu/g) (cfu/g) count (cfu/g) Day 2Negative 280 230 <10 Day 2 Negative 290 160 <10

Example 17 Viscosity Enabler

Product was prepared in 20 oz cans, 567.0 g product and 5.5 g CO₂) oralternatively was a commercially available (Aunt Jemima) batter preparedaccording to the directions. Both products were stored at underapproximately 4° C. (40° F.).

The batter needs to flow at a certain rate for an optimal product. Thusit needs a certain viscosity. In an embodiment of the invention, the CO₂is used to insure that the product does not separate or degrade and theviscosity remains relatively stable as shown in Table 17.1.

TABLE 17.1 Comparison of Viscosity of Pressurized product withcommercial pancake mix. Carbon Dioxide Aunt Jemima no gas Can date Feb.24, 2007 Single can spray out 3 ounce per test Pour out 3 ounce per testEst. shelf life Chilled 120 days Freeze thaw product Day 1 Viscositytest meters 13800 Viscosity test meter 16800 CO₂ gassed at 150 psiStored at 40° F. CO₂ in can 6 grams Batter has nice consistency easy toHeld at 40° F. pour. Day 15 Viscosity is at its highest point orViscosity test meter 8400 thickest point before the Co2 can Bacteriagrowth and moisture saturate the batter. separation. Viscosity testmeters 13000 Consistency is thin. CO₂ has totally saturated the batterthus stabilizing the batter. Consistency is light and fluffy Day 30Viscosity test meter 13200 Viscosity test meter 7600 Less batter in thecan creates more Bacteria growth, off odor and head space for CO₂moisture separation Consistency is light and fluffy. Batter unusable.Day 45 Viscosity test meter 13200 Test meter could not measure becauseConsistency light fluffy solids and liquid had separated. Day 60Viscosity test meter 13100 N/A Consistency light fluffy Day 120Viscosity test meter 13000 Consistency light fluffy End of the can hasextra amount of CO₂ pressure released Fill 200z 16 oz CO₂ weight 6 gaverage   0 Can pressure ~150 (start) ~0 ~130 (overnight, no shaking)

Example 18 Browning of Product

Product was prepared as shown in Table 15.1 (20 oz cans 567.0 g productand 5.5 g CO₂) or alternatively was a commercially available (AuntJemima) batter prepared according to the directions. Both products werestored at under approximately 4° C. (40° F.).

FIG. 5 (black and white) and FIG. 6 (color) show a waffle (10) and apancake (20) which were dispensed from a pressurized canister containingcarbon dioxide. In comparison, the same batter applied directly to thewaffle iron (30) or frying pan (40) was baked for the same length oftime at the same temperature. The carbon dioxide gas allows for the easyflow of the batter from the pressurized canister and also aerates thebatter mix. Unexpectedly, the carbon dioxide results in a brownishappearance, crunchy texture and attractive taste to the food product.The carbon dioxide's attractive browning of the waffle or pancakethereby allows the food product to be baked more rapidly andefficiently. The carbon dioxide improves the taste experience of theperson consuming the food product.

DEFINITION OF TERMS

Clayton: Clayton Corporation; supplier of valves and caps.

Delivery Weight: the total amount of product sprayed after all thepressure in the can is exhausted.

Bakable: including frying, steaming, toasting, boiling, grilling andcooking including cooking on a waffle iron, cooking on a frying pan andcooking in an oven.

Browning: refers to the color of the bakable food product upon bakingand corresponds with the oxidation of one or more of the carbonaceouscomponents in the composition.

Light and Fluffy: easily cut with a plastic knife. Pancake or foodproduct retains shape and form after being compressed. Does not requiremetal knife or excessive force to cut or slice food product. Foodproduct is not heavy or dense and plastic knife does not permanentlycompress food product at a distance of 2 mm from the knife blade whencutting food product. Food product does not result in heavy feeling instomach or other discomfort when eaten. See also sponge-like.

Propellant(s): compressed gas Carbon Dioxide (CO₂) or Nitrogen (N₂) or acombination of both.

Resident Microorganism: chief microbial flora or the microorganismnormally existing in the product.

Retention or Retention Weight: the amount of product remaining in thecan after all the pressure in the can is exhausted.

Sponge-like: having the characteristics of a sponge; bread withconsistent size of air pockets as in sponge cake; a desirablecharacteristic of a pancake.

Spray Rate: amount of product sprayed out of a can at a given amount oftime; typically in grams per 1 second spray.

Summit: Summit Packaging Systems, Inc.; supplier of valves andactuators.

Water: de-ionized water.

It is to be understood that other embodiments of the invention can bedeveloped and fall within the spirit and scope of the invention andclaims

1. A packaged food product comprising: an unpasteurized pancake andwaffle batter including a plurality of raw ingredients mixed at atemperature below about 4° C., the batter having a water activity ofapproximately 0.96; said batter sealed in a dispenser; the dispenserpressurized with a gas; the dispenser having a valve through which saidbatter can be manually dispensed; wherein said batter, when sealed andpressurized in said dispenser, has a refrigerated shelf-life greaterthan approximately 120 days.
 2. The packaged food product of claim 1,wherein the said batter comprises: flour, sugar and egg mixed with waterat a temperature below about 4° C., the batter having a water activityof approximately 0.96.
 3. The packaged food product of claim 1, whereinsaid batter comprises: flour, sugar, sodium lactate, and egg mixed withwater at a temperature below about 4° C., the batter having a wateractivity of approximately 0.96.
 4. The packaged food product of claim 1,wherein said batter comprises: flour, sugar, cultured dextrose, and eggmixed with water at a temperature below about 4° C., the batter having awater activity of approximately 0.96.
 5. The packaged food product ofclaim 1, wherein said batter has a viscosity greater than approximately12000 cP.
 6. The packaged food product of claim 1, wherein said batterhas a viscosity less than approximately 14000 cP.
 7. The packaged foodproduct of claim 1, wherein said batter has a viscosity greater thanapproximately 12000 cP and less than approximately 14000 cP.
 8. Thepackaged food product of claim 1, wherein the batter has a pH ofapproximately
 6. 9. The packaged food product of claim 1, wherein saidgas includes carbon dioxide.
 10. The packaged food product of claim 1,wherein said gas includes carbon dioxide and wherein the batter whenpressurized with said gas is phase stable over a temperature rangebetween: a lower limit of approximately −5° C.; and an upper limit ofapproximately 35° C.
 11. A packaged food product comprising: anunpasteurized pancake and waffle batter including a plurality of rawingredients mixed at a temperature below about 4° C., the batter havinga water activity of approximately 0.96; said batter sealed in adispenser; the dispenser pressurized with a water soluble gas; thedispenser having a valve through which said batter can be manuallydispensed; wherein said batter, when sealed and pressurized in saiddispenser, has a refrigerated shelf-life greater than approximately 120days.
 12. The packaged food product of claim 11, wherein the said battercomprises: flour, sugar and egg mixed with water at a temperature belowabout 4° C., the batter having a water activity of approximately 0.96.13. The packaged food product of claim 11, wherein said battercomprises: flour, sugar, sodium lactate, and egg mixed with water at atemperature below about 4° C., the batter having a water activity ofapproximately 0.96.
 14. The packaged food product of claim 11, whereinsaid batter comprises: flour, sugar, cultured dextrose, and egg mixedwith water at a temperature below about 4° C., the batter having a wateractivity of approximately 0.96.
 15. The packaged food product of claim11, wherein said batter has a viscosity greater than approximately 12000cP.
 16. The packaged food product of claim 11, wherein said batter has aviscosity less than approximately 14000 cP.
 17. The packaged foodproduct of claim 11, wherein the batter has a pH of approximately
 6. 18.The packaged food product of claim 11, wherein said gas includes carbondioxide.
 19. The packaged food product of claim 11, wherein said gasincludes carbon dioxide and wherein the batter when pressurized withsaid gas is phase stabile over a temperature range between: a lowerlimit of approximately −5° C.; and an upper limit of approximately 35°C.
 20. A packaged food product comprising: an unpasteurized pancake andwaffle batter including a plurality of raw ingredients including flour,sugar and egg, mixed with water at a temperature below about 4° C., thebatter having a water activity of approximately 0.96; said batter sealedin a dispenser; the dispenser pressurized with a gas including carbondioxide; the dispenser having a valve through which said batter can bemanually dispensed; and wherein said batter, when sealed and pressurizedin said dispenser has a viscosity greater than approximately 12000 cPand less than approximately 14000 cP, a refrigerated shelf-life greaterthan approximately 120 days, and wherein said batter is phase stabileover a temperature range between −5° C.; and 35° C.